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Copier

d-Copia 12
SERVICE MANUAL
Code Y101700-5

PUBBLICATION ISSUED BY:


Olivetti TECNOST S.p.A.
Documentazione
77, Via Jervis - 10015 Ivrea (Italy)

Copyright 2002, Olivetti


All rigths reserved

CAUTION
This product is a class 1 laser product that complies with 21CFR 1040.10 and 1040.11 of the CDRH standard and IEC825. This
means that this machine does not produce hazardous laser radiation. The use of controls, adjustments or performance of
procedures other than those specified herein may result in hazardous radiation exposure.
This laser radiation is not a danger to the skin, but when an exact focusing of the laser beam is achieved on the eyes retina, there
is the danger of spot damage to the retina.
The following cautions must be observed to avoid exposure of the laser beam to your eyes at the time of servicing.
1) When a problem in the laser optical unit has occurred, the whole optical unit must be exchanged as a unit, not as individual
parts.
2) Do not look into the machine with the main switch turned on after removing the developer unit, toner cartridge, and drum
cartridge.
3) Do not look into the laser beam exposure slit of the laser optical unit with the connector connected when removing and
installing the optical system.
4) The middle frame contains the safety interlock switch.
Do not defeat the safety interlock by inserting wedges or other items into the switch slot.

Y101700-5

Service Manual

vi

Service Manual

Y101700-5

1. GENERAL
1.1 Main features
The d-Copia 12 copier has the following major
characteristics:
-

High-speed laser copying


Since warm-up time is zero, copying can be started
immediately after the power switch is turned on.
First-copy time is only 9.6 seconds (normal mode).
Copying speed is 12 copies/min. which adapts to business use, allowing improvement of working efficiency.

- Digital high-quality image


High-quality image copying with 600 dpi can be performed.
In addition to the automatic exposure mode, the manual
exposure can be adjusted in five steps.
The photo mode copying function which allows clear
copying of delicate halftone original images such as
monochrome photos and color photos can be used.

Y101700-5

- Substancial copying functions


Zoom copying from 50% to 200% in 1% increments can
be performed.
A maximum of 99 copies can be selected.
Toner save mode for reducing toner consumption by
approximately 10% can be set.
- Environmentally friendly design
Paper output tray is housed in the copier for space
saving.
Preheat mode and auto power shut-off mode are provided to reduce power consumption in standby mode.
- Printer feature
This copier is also a laser printer.

Service Manual

1-1

1.2 Specifications
1.2.1 Basic specifications of the copier
A. Basic specifications

Item

Spec.

Type
Copy system
Segment (class)
External dimensions (W D H) (mm)
Weight

Desktop
Dry, electrostatic
Digital personal copier
518 mm 482.6 mm 292.6 mm
Approx. 19Kg, (drum cartridges included)

B. Operation specifications

Section

Item

Details

Paper feed
system

1 tray (250 sheets) + 1 single-sheet manual bypass


Paper size
Paper weight
Paper feed capacity
Kinds
Remark

A4, B5, A5 (Landscape)


56 80g/m2 Tray paper
250 sheets
Standard paper, specified paper, recycled paper
User adjustment of paper guide available

Paper size
Paper weight
Kinds *1
Remark

A4, B5, A5, B6, A6 (Landscape)


52 128g/m2
Standard paper, specified paper, recycled paper, OHP, Label,
Postal card
User adjustment of paper guide available

Tray paper
feed section

Paper size
Paper weight
Paper feed capacity
Kinds
Remark

8-1/2 14, 8-1/2 11, 8-1/2 5-1/2 (Landscape)


15 21 lbs.
250 sheets
Standard paper, specified paper, recycled paper
User adjustment of paper guide available

Single-sheet
manual bypass
feed section

Paper size

8-1/2 14, 8-1/2 11, 8-1/2 5-1/2, 3-1/2 5-1/2


(Landscape)
14 34.5 lbs.
Standard paper, specified paper, recycled paper, OHP, Label,
Postal card
User adjustment of paper guide available

Tray paper
feed section
AB system
Single-sheet
manual bypass
feed section

Paper
feed
setion

Spec.

Inch system

Paper weight
Kinds *1
Remark

1: OHP, Label, Postal card: each 1 pc.

1-2

Service Manual

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Section

Item

Details

Spec.

Paper exit

Exit way

Face down

section

Capacity of output tray

100 sheets

Original set

Center Registration (left edge)

Max. original size

B4 (10 14)

Original kinds

sheet

Original size detection

None

Scanning system

CCD sensor scanning by


lighting lamp scanner

Originals

CCD sensor
Optical
section

Scanning
section

Lighting lamp

Resolution
Type
Voltage
Power consumption

Gradation
Writing
section

Image forming

Writing system

Writing to OPC drum by the


semiconductor laser

Laser unit

Resolution
Type

OPC (30)

Photoconductor

Life

18k

Charging system

Saw -tooth charging with a


grid, / () scorotron discharge

Charger
Separation system

Transfer system

(+) DC corotron system


() DC corotron system

Developing

Developing system

Dry, 2-component magnetic


brush development system

Cleaning

Cleaning system

Counter blade system


(Counter to rotation)

Fusing system

Fusing section

400 dpi
Xenon lamp
1.5kV
11 3W
256 gradations/8bit

600 dpi

Heat roller system

Upper heat roller

Type

Teflon roller

Lower heat roller

Type

Silicon rubber roller

Type

Halogen lamp

Heater lamp

Voltage

100V

Power consumption

800W

Voltage

Local AC voltage

Frequency

Common use for 50 and 60Hz

Power source

Electrical section
Power consumption

Max.

1000W

Average (during copying) *1)

310Wh/H

Average (stand-by) *1)

70Wh/H

Pre-heat mode *1)

40Wh/H

Auto power shut-off mode *1)

18Wh/H

*1) May fluctuate due to environmental conditions and the input voltage.

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Service Manual

1-3

C. Copy performance

Section
Copy
magnification

Item

Details

Fixed magnification ratios

3R + 2E (AB system: 50, 70,


81, 100, 141, 200%)
(Inch system: 50, 64, 78, 100,
129, 200%)
50 200% (151 steps in 1%
increments)

Zooming magnification ratios

Manual steps (manual,


photo)

Copy speed

Spec.

5 steps

Tray paper feed

9.6 sec. or below (A4), 9.4 sec.


or below (8-1/2" 14")
Pre-heat mode: 16 sec.
or below / Auto powershut-off mode: 23 sec. or
below)

Manual paper feed

10.0 sec (Pre-heat mode: 16


sec. or below / Auto
power-shut-off mode: 23 sec.
or below)

First copy time

AB system: A4
(Landscape)

Copy speed (CPM)

Same size
Enlargement
Reduction

12
12
12

B5 (Landscape)

Copy speed (CPM)

Same size
Enlargement
Reduction

12
12
12

Inch system 8-1/2

Copy speed (CPM)

Same size

10

Enlargement
Reduction

10
10

Same size
Enlargement
Reduction

12
12
12

14 (Landscape)

8-1/2 11
(Landscape)

Copy speed (CPM)

Max. continuous copy


quantity

Void

99

Leading edge

1 4mm

Trailing edge

4mm or less, 6mm or less

Void area
4.0mm or less (per side),

Image loss

OC mode

Side edge void area

machine with side edge void


0.5mm 4mm (Total of both
edge voids)

Leading edge

Same size: 3.0mm or less /


Enlarge (200%): 2.0mm
or less / Reduction (50%):
6.0mm or less

Warm-up time

0 sec.

Power save mode reset time

0 sec.

Paper jam recovery time

0 sec.

1-4

Service Manual

Y101700-5

1.3 Consumables
1.3.1 Supply system table

No.

Name

Content

Life

Toner CA (Black)
with CA

Toner
(Toner Net Weight 210g)
Polyethylene bag

x10

Package

6.5K
per unit

x10

Developer

Developer
(Developer Net Weight 170g)

x10

25K
per unit

Drum kit

Drum
Drum fixing plate

x1
x1

25K

10

Note: Packed together with the machine: DR 25K/Developer UN/Process UN.

Y101700-5

Service Manual

1-5

1.4 Environmental conditions

1.5 Production control number


(lot No.) identification

The environmental conditions for assuring the copy


quality and the machine operations are as follows:

(Developing cartridge)

- Normal operating condition


Temperature:20C~25
Humidity:65 5%RH

- Acceptable operating condition


*: Destination
Division

- Optical condition

No.

EX Destination

A same pack
B same pack

G
H

Option Destination

A
B

P
Q

(Drum cartridge)
The label on the drum cartridge shows the date of
production (SOCC production).

(JAPAN production)

- Supply storage condition

1-6

Service Manual

Y101700-5

1.6 TD cartridge replacement


Division

No.

Ex production
Option
Same pack

1
2
3

1) Open the front and side cabinets of the copier.


2) Keep holding Toner lover, and
3) Carefully pull out Toner unit from the copier.

4) Put Toner unit in a collection bag immediately after removing


it from the copier.

*1 The production control label is not attached to the cartridge


of a China product.

Note: Never carry exposed Toner unit. Be sure to put it in the


collection bag.

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Service Manual

1-7

1.7 External views and internal components


1.7.1 General appearance

9
1

2
3
7

11

13

10

12

15
16

14

13

17

18
22
20

21

19
1
2
3
4
5
6
7
8
9
10
11

Original cover
Side cover
Manual bypass
Paper guides
Side cover open button
Front cover
Paper tray
Operation panel
Original table
Parallel interface
Paper output tray

1-8

12
13
14
15
16
17
18
19
20
21
22

Paper output tray extension


Handle
Power switch
Power cord socket
Toner cartridge lock release lever
Toner cartridge
Transfer charger
Photoconductive drum
Charger cleaner
Fusing unit release tab
Paper feed roller

Service Manual

Y101700-5

1.8 Operation panel

1 Exposure mode selector key and indicators


Use to sequentially select the exposure modes: AUTO, MANUAL (= ) or PHOTO ( ). Selected mode is shown by a
lit indicator.
2 Light ({) and dark ( ) keys and exposure indicators
Used to adjust the MANUAL (=) or PHOTO ( ) exposure
level. Selected exposure level is shown by a lit indicator.
Use to start and terminate user program setting.
3 Alarm indicators
q: Developer replacement required indicator.
t : Misfeed indicator.
s : Toner cartridge replacement required indicator.
p : Maintenance indicator.
4 Copy ratio selector key and copy ratio indicators
Use to sequentially select prset reduction/enlargement copy
ratios.
5 Zoom indicator
6 Copy ratio display (%) key
7 Display
Displays the specified copy quantity, zoom copy
ratio, user program code, and error code.

Y101700-5

8 ON LINE indicator
Lights up when the machine is used as a printer or when it is
receiving or processing print data.
9 Power save indicator
Lights up when the copier is in a power save mode.
0 Zoom keys (N, L)
Use to select any reduction or enlargement copy
ratio from 50 to 200% in 1% increments.
q Copy quantity keys ( ,
)
Use to select the desired copy quantity (1 to 99).
Use to make user program entries.
w Clear key (>)
Press to clear the display, or press during a copy run to
terminate copying.
Press and hold down during standby to display the total
number of copies to date.
e Print key and ready indicator ( )
Copying is possible when the indicator is on.
Use to set a user program.

Service Manual

1-9

1.9 Motors and solenoids

No.

Part name

Control signal

Function operation

Toner motor

TM

Supplies toner

Mirror motor

MRMT

Drives the optical mirror base


(scanner unit)

Cooling fan motor

VFM

Cools the optical section

Main motor

MM

Drives the copier

Resist roller solenoid

RRS

Resist roller rotation control solenoid

Paper feed solenoid

CPFS1

Cassette paper feed solenoid 1

1-10

Service Manual

Y101700-5

1.10 Sensors and switches

No.

Name

Signal

Type

Function

Output

Mirror home
position sensor

MHPS

Transmission sensor

Mirror (scanner unit)


home pos. detection

H at home pos.

POD sensor

POD

Transmission sensor

Paper exit detection

H at paper pass

SPPD sensor

SPPD

Transmission sensor

Paper transport detection

L at paper pass

PPD2 sensor

PPD2

Transmission sensor

Paper transp. detection 2

L at paper pass

Cassette detect.
switch

CED1

Microswitch

Cassette installation
installation

H at cass. insert.

PPD1 sensor

PPD1

Transmission sensor

Paper transp. detection 1

L at paper pass

PPD3 sensor

PPD3

Transmission sensor

Paper transp. detection 3

L at paper pass

Door switch

DSW

Microswitch

Door open/close detect.


(safety switch for 5V)

1 or 0V or 5V at
door open

Door switch

DSW

Microswitch

Door open/close detect.


(safety switch for 24V)

1 or 0V or 24Vat
door open

Y101700-5

Service Manual

1-11

1.11 PWB unit

No.

Name

Function

Exposure lamp invertor PWB

Exposure lamp (Xenon lamp) control

GDI PWB

For GDI interface

Main PWB (MCU)

Copier control

Memory PWB 4MB

For memorizing data

LSU PWB

For laser control

LSU motor PWB

For polygon motor drive

TCS PWB

For toner sensor control

Operation PWB

Operation input/display

CCD sensor PWB

For image scanning

10

Power PWB

AC power input, DC voltage control, High voltage control

1-12

Service Manual

Y101700-5

1.12 Cross sectional view

No.

Part name

Function and operation

Paper exit roller

Roller for paper exit

Lens unit

Scans the original image with the lens and the CCD

LSU (Laser unit)

Converts the original image signal into laser beams and writes onto
the drum

Main charger

Provides negative charges evenly to the drum surface

Scanner unit

Illuminates the original with the copy lamp and passes the reflected
light to the ens unit (CCD)

Exposure lamp

Exposure lamp (Xenon lamp) Illuminates original

Heat roller

Fuses toner on the paper (Teflon roller)

Pressure roller

Fuses toner on the paper (Silicon rubber roller)

Drum

Forms images

10

Transfer unit

Transfers images onto the drum.

11

Manual paper feed


roller

Transport the paper from the manual paper feed port

12

PS roller unit

Takes synchronization between the lead edge and the rear edge of
the paper

13

Paper feed roller

Picks up a sheet of paper from the cassette

Y101700-5

Service Manual

1-13

1-14

Service Manual

Y101700-5

2. UNPACKING AND
INSTALLATION
2.1 Copier installation
Improper installation may damage the copier. Please
note the following during initial installation and whenever
the copier is moved.
Caution: If the copier is moved from a cool place to a
warm place, condensation may form inside the
copier. Operation in this condition will cause
poor copy quality and malfunctions. Leave the
copier at room temperature for at least 2 hours
before use.

2.2 Cautions on handling


Be careful in handling the copier as follows to maintain the
performance of this copier.
Do not drop the copier, subject it to shock or strike it
against any object.

Do not install your copier in areas that are:


damp, humid, or very dusty

exposed to direct sunlight


Do not expose the drum cartridge to direct sunlight.
Doing so will damage the surface (green portion) of the
drum cartridge, causing poor print quality.

poorly ventilated

Store spare supplies such as drum cartridges and TD


cartridges in a dark place without removing from the package
before use.

subject to extreme temperature or humidity


changes, e.g., near an air conditioner or heater.

If they are exposed to direct sunlight, poor print quality


may result.
Do not touch the surface (green portion) of the drum
cartridge.
Doing so will damage the surface of the cartridge, causing poor print quality.

The copier should be installed near an accessible


power outlet for easy connection. Be sure to connect the
power cord only to a power outlet that meets the specified
voltage and current requirements. Also make certain the
outlet is properly grounded.
Be sure to allow the required space around the machine for servicing and proper ventilation.

Y101700-5

Service Manual

2-1

2) Use a coin (or suitable object) to remove the screw.


Store the screw in the paper tray because it will be used if
the copier has to be moved.

2.3 Checking packed components and


accessories
Open the carton and check if the following components
and accessories are included.

Power cord

Interface
cable

2.6 Developer unit installation

Copier
Drum cartridge
(installed in copier)

1) 2) 3) Open the side and front cabinets of the copier.


4) Remove the locking tape of the developer unit.
5) Remove the screw which is fixing the copier and Developer
unit.
6) Remove Developer unit slowly from the copier.

2.4 Unpacking
Be sure to hold the handles on both sides of the copier to
unpack the copier and carry it to the installation location.

2.5 Removing protective packing


materials

7) Remove the screw (1 pc).


8) Remove Upper developer unit.

1) Remove pieces of tape and protective cover. Then open


the original cover and remove protective materials (a)
and (b).

2-2

Service Manual

Y101700-5

9) Shake the aluminum bag to stir developer.


10) Supply developer from the aluminum bag to the top of
the MX roller evenly.

2.7 Toner cartridge installation


1) To prevent against uneven distribution of toner, hold
Toner unit with both hands and shake it several times
horizontally.

2) Hold the section of Toner unit shown in the figure below,


remove the packing tape, and remove the cushion.
3) Pull out the cushion in the arrow direction.
Note: Be careful not to splash developer outside Developer
unit.
11) Attach Upper developer unit and fix it with a screw.
12) Rotate the MG roller gear to distribute developer evenly.

4) Insert Toner unit carefully into the copier.


5) Insert until the hook is engaged with the copier as shown
in the figure below.

Note: Never rotate the gear in the reverse direction.


Note: When carrying Developer unit, do not tilt it extremely as shown with the arrow in the figure below.
(Prevention of splash of developer)

13) Insert Developer unit carefully into the copier.


Note: Quick insertion may result in splash of developer. Be
sure to insert carefully.
14) Confirm that Developer unit is completely inserted to
the bottom of the machine, fix Developer unit and the
machine with a screw.
15) Completion of Developer unit installation.

Y101700-5

Service Manual

2-3

5) Fan the copy paper and insert it into the tray. Make sure
the edges go under the corner hooks.

6) Pull out the shutter in the arrow direction.

Note: Do not load paper above the maximum height line


(
). Exceeding the line will cause a paper misfeed.

Note: Do not hold and carry the shutter. Otherwise the


shutter may drop and Toner unit may drop.
7) Completion of Toner unit installation
Close the front and side cabinets.

6) Gently push the paper tray back into the copier.

2.8 Loading copy paper


1) Raise the handle of the paper tray and pull the paper
tray out until it stops.

2) Remove the pressure plate lock. Rotate the pressure


plate lock to remove it while pressing down the pressure
plate of the paper tray.
3) Store the pressure plate lock which has been removed
in step 2 and the screw which has been removed when
unpacking (see REMOVING PROTECTIVE PACKING
MATERIALS) in the front of the paper tray.
To store the pressure plate lock, rotate the lock to fix it
on the relevant location.
4) Adjust the paper guides on the paper tray to the copy
paper width and length.
Squeeze the lever of paper guide (A) and slide the guide
to match with the width of the paper.
Move paper guide (B) to the appropriate slot as marked
on the tray.

2-4

Note: After loading copy paper, to cancel the blinking P


without restarting copying, press the clear (>) key.
The P in the display will go out and the ready ( )
indicator will light up.

2.9 Power to copier


1) Ensure that the power switch of the copier is in the OFF
position. Insert the attached power cord into the power
cord socket at the rear of the copier.
2) Plug the other end of the power cord into the nearest
outlet.

Service Manual

Y101700-5

3.

OPERATIONAL DESCRIPTIONS

3.1 Outline of operation


The outline of operation is described referring to the basic configuration.

Outline of copy operation


Setting conditions
1) Set copy conditions such as the copy quantity and the copy density with the operation section, and press the COPY button.
The information on copy conditions is sent to the MCU.
Image scanning
2) When the COPY button is pressed, the scanner section starts scanning of images.
The light from the copy lamp is reflected by the document and passed through the lens to the CCD.
Photo signal/Electric signal conversion
3) The image is converted into electrical signals by the CCD circuit and passed to the MCU.
Image process
4) The document image signal sent from the CCD circuit is processed under the revised conditions and sent to the LSU (laser
unit) as print data.
Electric signal/Photo signal (laser beam) conversion
5) The LSU emits laser beams according to the print data.
(Electrical signals are converted into photo signals.)
6) The laser beams are radiated through the polygon mirror and various lenses to the OPC drum.
Printing
7) Electrostatic latent images are formed on the OPC drum according to the laser beams, and the latent images are developed
to be visible images (toner images).
8) Meanwhile the paper is fed to the image transfer section in synchronization with the image lead edge.
9) After the transfer of toner images onto the paper, the toner images are fused to the paper by the fusing section. The copied
paper is discharged onto the exit tray.

Y101700-5

Service Manual

3-1

3.2 Scanner section


3.2.1 How to scan documents
The scanner has sensors that are arranged in a line.
These sensors scan a certain area of a document at a time
and deliver outputs sequentially. When the line is finished, the
next line is scanned, and this procedure is repeated.
The figure on the side shows the case where the latter
two sections of an image which are scanned are shown
with solid lines and the former two sections which are being
transmitted are shown with dotted lines.
The direction of this line is called main scanning direction, and the scanning direction sub scanning direction.
With reference to the figure, one line is divided into 4
sections. Actually, however, one line is divided into thousands of sections. For scanning, the light receiving element
called CCD is used.
The basic resolution indicates the scanner capacity. The
basic resolution is expressed in dpi (dot/inch) which shows
the number of light emitting elements per inch on the document.
The basic resolution of this machine is 400dpi.
In the sub scanning direction, at the same time, the motor
that drives the optical system is controlled to scan the image
at the basic resolution.

3.2.2 Basic structure of scanner section

Copy lamp (Xenon lamp)

Reflector (light conversion plate)

No. 1 mirror

No. 2 mirror

No. 3 mirror

Lens

No. 2/3 mirror unit

Copy lamp unit

CCD

10

Mirror motor

11

MHPS (Mirror home position sensor)

The scanner unit performs scanning in the digital optical system. The light from the light source (Xenon lamp) is reflected by
a document and passed through three mirrors and reduction lenses to the CCD element (image sensor) where images are
formed. This system is known as the reduction image sensor system. Photo energy on the CCD element is converted into
electrical signals (analog signals). (Photo-electric conversion). The output signals (analog signals) are converted into digital
signals (A/D conversion) and passed to the MCU (main control/image process section). The resolution at that time is 400dpi.
The mirror unit in the scanner section is driven by the mirror motor. The MHPS is provided to detect the home position of the copy
lamp unit.

3-2

Service Manual

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3.3 Laser unit


The image data sent from the MCU (image process
circuit) is sent to the LSU (laser unit), where it is converted
into laser beams.

Makes the laser scanning speeds at both ends of the drum


same as each other.

3.3.1 Basic structure


The LSU unit is the writing section of the digital optical
system. The semiconductor laser is used as the light source,
and images are formed on the OPC drum by the polygon
mirror and f lens, etc. The laser beams are passed through
the collimator lens, the cylindrical lens, the polygon mirror,
the f lens, and the mirror to form images on the OPC drum
in the main scanning direction. The laser emitting PWB is
provided with the APC (auto power control) in order to
eliminate fluctuations in the laser power. The BF PWB
works for measurement of the laser writing start point.

3.3.2 Laser beam path

Laser beam
path for BF PWB

No.

Component

(1)
(2)

Semiconductor laser
Collimator lens

(3)
(4)
(5)

Function

Generates laser beams.


Converges laser beams in
parallel.
Polygon mirror,
Reflects laser beams at a
polygon motor
constant rpm.
BD (Mirror, lens, PWB) Detects start timing
of laser scanning.
f lens
Converges laser beams at
a spot on the drum.
Makes the laser scanning
speeds at both ends of
the drum same as each
other (refer to the

figure below).

Y101700-5

3.3.3 Composition
Effective scanning width:
Resolution:
Beam diameter:

Image surface power:


Polygon motor section:

Service Manual

216mm (max.)
600dpi
75um in the main scanning
direction, 80um in the sub
scanning direction
0.20 0.03mW (Laser
wavelength780 795nm)
Brushless motor 20.787rpm
No. of mirror surfaces: 6
surfaces

3-3

(3) Thermal control


1. The heater lamp, thermistor, main PWB, DC power
supply PWB, and triac within the power supply unit are
used to control the temperature in the fuser unit.
To prevent against abnormally high temperature in the
fuser unit, a thermal breaker and thermal fuse are used for
safety purposes.

3.4 Fuser section

Heated by the heater


lamp (950 W)

Safety device (thermal


breaker, thermal fuse)

3.4.1 General description

The surface temperature


of the upper heat roller is
sensed by the termistor.

General block diagram (cross section)

Triac (in the power


supply unit)

Level of the thermistor


is controlled by the
main PWB
With the signal from the
main PWB, the triac is
controlled on and off
(power supply PWB)

2. The surface temperature of the upper heat roller is set


to 165C ~ 190C. The surface temperature during the
power save mode is set to 100C.

(1) Heat roller


A Teflon roller is used for the heat roller and a silicone
rubber roller is used for the lower heat roller for better toner
fusing performance and paper separation.
(2) Separator pawl
Three separator pawls are used on the upper heat roller. The
separator pawls are teflon coated to reduce friction with the
roller and prevent a smear on the paper caused by the
separator pawl.

3-4

3. The self-check function comes active when one of the


following malfunctions occurs, and an H is displayed on
the multicopy window.
a. When the heat roller surface temperature rises above
240C.
b. When the heat roller surface temperature drops below
100C during the copy cycle.
c. Open thermistor
d. Open thermal fuse
e. When the heat roller temperature does not reach
190C within 27 second after supplying the power.
(4) Fusing resistor
Fusing resistor
This model is provided with a fusing resistor in the fusing
section to improve transfer efficiency.
General descriptions are made in the following.
General descriptions
Since the upper heat roller is conductive when copy paper is
highly moist and the distance between the transfer unit and
the fusing unit is short, the transfer current leaks through the
copy paper, the upper heat roller and the discharging brush.

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Y101700-5

3.5 Paper feed section and paper transport section


3.5.1 Paper transport path and general operations

(1)

Scanner unit

(6)

Main charger

(11)

Pickup roller

(2)

Copy lamp

(7)

Heat roller

(12)

Manual paper feed roller

(3)

Lens unit

(8)

Pressure roller

(13)

PS roller unit

(4)

LSU (Laser unit)

(9)

Drum

(14)

Paper feed roller

(5)

Paper exit roller

(10)

Transfer unit

Paper feed is made in two ways; the cassette paper feed and the manual paper feed. The cassette is of universal-type, and
has the capacity of 250 sheets.

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3-5

3.5.2 Cassette paper feed operation


1) The figure below shows the positions of the pick-up
roller, the paperfeed clutch sleeve, and the paper feed
latch in the initial state without pressing the COPY
button after lighting the ready lamp. The paper feed
latch is in contact with the projection of the clutch sleeve.

5) At this time, the paper is fed past the paper entry detection
switch (PPD1), and detected by it. After about 0.15 sec
from detection of paper by PPD1, the tray paper feed
solenoid (PFS) turns on so that the clutch sleeve projection
comes into contact with the paper feed latch to stop the
pick-up roller. Then the pick-up roller rotates for about
0.15 sec so that the lead edge of the paper is evenly
pressed on the resist roller, preventing against skew
feeding.

2) When the COPY button is pressed, the main drive motor


starts rotating to drive each drive gear.The pick-up
drive gear also is driven at that time. Since, however, the
paper feed latch is in contact with the projection of the
clutch sleeve, rotation of the drive gear is not transmitted
to the pick-up roller, which does not rotate.

3) After about 0.1 sec from when the main motor starts
rotating, the tray paper feed solenoid (PFS) turns on
momentarily.
This disengages the paper feed latch from the projection
of the clutch sleeve, transmitting rotation of the pick-up
drive gear to the paper feed roller shaft, rotating the pickup roller to feed the paper.

4) After more than half rotation of the pick-up roller, the


paper feed latch is brought in contact with the projection
of the clutch sleeve, stopping rotation of the pick-up
roller.

3-6

6) To release the resist roller, the tray paper feed solenoid


and the resist solenoid are turned on by the paper start
signal to disengage the resist start latch from the clutch
sleeve projection, transmitting rotation of the resist drive
gear to the resist roller shaft. Thus the paper is transported
by the resist roller.
7) After the resist roller starts rotating, the paper is passed
through the pre-transfer guide to the transfer section.
Images are transferred on the paper, which is separated
from the OPC drum by the drum curve and the separation
section.

8) The paper separated from the drum is passed through


the fusing paper guide, the heat roller (fusing section),
POD (paper out detector) to the copy tray.

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Y101700-5

4. DISASSEMBLY AND ASSEMBLY


Before disassembly, be sure to disconnect the power cord
for safety.
The disassembly and assembly procedures are described
for the followingn sections:
1. High voltage section
2. Operation panel section
3. Optical section
4. Fusing section
5. Cassette paper feed/transport section
6. Manual paper feed section
7. Rear frame section
8. Power section

2) Remove the drum fixing plate and the photoconductor


drum.
Note: Dispose the drum fixing plate which was removed.

4.1 High voltage section


4.1.1 List of parts
No.

Part name Ref.

1
2
3

Drum
Transfer charger unit
Charger wire

4.1.2 Drum replacement


1) Remove the drum cover. (4 Lock Tabs)

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3) Check the cleaning blade and the red felt for no damage.
If there is any damage, execute all procedures from
item 5) and later.
If there is no damage, execute the procedure of item 12).
4) Remove the main charger.
(Cleaning the screen grid and the sawteeth.)

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4-1

5) Remove the cleaning blade.


Note: Dispose the cleaning blade which was removed.

6) Clean the cleaning section and the waste toner pipe to


remove waste toner completely with a vacuum cleaner.
7) Remove the felt and duplex tape completely.
Note: Be careful not to scratch or bend the sub blade.
8) Attach the cleaning blade.
Securely insert the plate section of the cleaning blade into
the unit and fix it with a screw.
Do not touch the cleaning blade rubber with your hand.
When attaching the cleaning blade, press the cleaning
blade in the arrow direction and attach.

Attach the mocket with slightly pressing the cleaning blade.


Do not touch the tip of the cleaning blade.
Do not put the mocket under the cleaning blade.
Do not put the mocket on the sub blade.
Do not press the sub blade with the mocket.
10) Attach the main charger.
Securely set the MC holder on the projection of the
process frame.
Securely insert two projections of the MC holder into the
groove in the process frame.
When attaching the MC holder assy, be careful not to
make contact with the cleaning blade.

11) Attach the drum fixing plate and the photoconductor


drum.
Apply grease to the inside of the photoconductor drum.

9) Attach the felt.

Attach the drum. (Prevention against the sub blade edge


breakage)
Attach the drum so that its position with the sub blade is as
shown.
12) Attach the drum cover.

4-2

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Y101700-5

(2) Push up the lock pawls (2 positions) of the side cover,


and remove the transfer charger.

4.1.3 Disassembly procedure


(1) Press the side cover open/close button and open the side
cover.

4.1.4 Assembly procedure


For assembly, reverse the disassembly procedure.

4.1.5 Charger wire cleaning


(1) Remove the charger cleaner from the manual paper
feed unit.

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Service Manual

4-3

(2) Set the charger cleaner to the transfer unit, and move it
reciprocally a few times in the arrow direction shown in
the figure below.

4.2 Operation panel section


4.2.1 List of parts
No.

Part name Ref.

1
2

Operation panel unit


Operation PWB

4.2.2 Disassembly procedure


(1) Remove the screws (4 pcs.), the harness, and the
operation panel unit.

4.1.6 Charger wire replacement


(1) Remove the TC cover and remove the screw.
(2) Remove the spring and remove the charger wire.
(3) Install a new charger wire by reversing the procedures
(1) and (2).
At that time, be careful of the following items.
The rest of the charger wire must be within 1.5mm.
The spring hook section (charger wire winding section)
must be in the range of the projection section.
Be careful not to twist the charger wire.

4-4

(2) Remove the screws (3 pcs.) and the PWB holder.


(3) Remove the screws (3 pcs.) and the operation PWB.

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4.2.3 Assembly procedure

(2) Remove the screws (2pcs.), and remove the copy lamp
unit from the mirror base drive wire.

For assembly, reverse the disassembly procedure.

4.3 Optical section


4.3.1 List of parts
No.
1
2
3

Part name Ref.


Copy lamp unit
Copy lamp
Lens unit

4.3.2 Disassembly procedure


(1) Remove the parts as shown below.

(3) Pull the copy lamp unit toward you to remove the harness.

(4) Remove the screw (4 pc) and remove the cover.

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Service Manual

4-5

(5) Remove the screws (2 pcs.), the harness, and the optical
unit.

4.4 Fusing section


4.4.1 List of parts
No.
1
2
3
4
5

Part name Ref.


Thermistor
PPD2 sensor
Heater lamp
Pressure roller
Heat roller

4.4.2 Disassembly procedure


(1) Remove the connectors (3 pcs.) of the rear cabinet.
(2) Open the side cover, remove two screws, and remove
the fusing unit.

When installing the lens unit, refer to Lens unit installation


reference in the next chapter.

4.3.3 Assembly procedure


Basically reverse the disassembly procedure.
The mirror base drive wire and the lens drive wire stretching
methods are described below.
a. Mirror base drive wire stretching
1. Hook the metal fixture of the mirror base drive wire on
the projection of the optical base plate.
2. Pass the wire through the external groove of the double
pulley. (At that time, check that No. 2/3 mirror unit is in
contact with the mirror base positioning plate.)
3. Hold so that the winding pulley groove is up, and wind the
mirror base drive wire 9 turns.
4. Put the 8th turn of the mirror base drive wire in the winding
pulley groove and fix with a screw.
5. Pass the wire under No. 2/3 mirror unit plate and wind it
around the pulley.
6. Pass the wire through the internal groove of the double
pulley and pass through the pulley.
7. Hook the spring hook on the optical base plate.

(3) Cut the binding band, remove the screw, and remove the
thermistor.

After installing the mirror base drive wire, be sure to


perform main scanning direction image distortion adjustment.

4-6

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Y101700-5

(7) Remove the plate spring on the right and remove the
heater lamp.

(4) Remove the screw and remove the U-turn guide.

4.4.2.1 Pressure roller section disassembly


(5) Remove the three screws, remove the fusing cover lower
on the right side, and open the heat roller section.

(8) Remove the spring and remove the separation pawls


(3 pcs).

(6) Remove the screw and remove the PPD2 sensor.

(9) Remove the E-ring and remove the reverse gate.

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Service Manual

4-7

(10) Remove the pressure release levers on the right and the
left sides.

(6) Remove the C-ring and the fusing bearing, and remove
the heat roller.

(7) Remove the parts from the heat roller.


Note: Apply grease to the sections specified with
(11) Remove the pressure roller, the pressure bearing, and
the spring.
Note: Apply grease to the sections specified with .

*.

(8) Remove two screws and remove the thermostat.

4.4.2.2 Heat roller disassembly


Continued from procedure (4).
(5) Remove screws, remove the fusing cover, and open the
heat roller section.

4.4.3 Assembly procedure


For assembly, reverse the disassembly procedure.

4-8

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4.5 Cassette paper feed/transport section

(3) Remove two screws and remove the toner motor.

4.5.1 List of parts


No.
1
2
3
4

Part name Ref.


PPD1 sensor PWB
LSU unit
Intermediate frame unit
Paper feed roller

4.5.2 Disassembly procedure


(1) Remove six connectors and screws of the main PWB,
and lift the optical unit and the main PWB to remove.

(4) Remove two springs and open the intermediate frame


unit.

(2) Remove the PWB insulation mylar and remove the paper
transport detection sensor (PPD2).

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4-9

(5) Remove the pulleys on the both sides and remove the
paper exit roller.

(7) Release the belt pulley lock and remove the belt pulley
bearing.

(6) Pull out the paper exit roller knob and remove the belt.

(8) Remove the paper exit roller.

4-10

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Y101700-5

(9) Remove the harness guide.

(11) Remove the parts as shown below, and remove the


pressure release solenoid and the paper feed solenoid.

(10) Remove five screws and remove the main drive plate
and the belt.

(12) Remove six screws and remove the LSU unit.

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4-11

(13) Remove two screws and remove the fusing connector.


(14) Remove five screws and the connector, and lift the
intermediate frame unit to remove.

(17) Remove three screws and remove the TC front paper


guide.

(18) Remove the screw and the connector, and remove the
PPD1 sensor PWB.

(15) Remove the screw and the E-ring, and remove the PS
semi-circular earth plate and the PS roller unit.
(16) Remove the E-ring and remove the spring clutch from
the PS roller unit.

4-12

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Y101700-5

(19) Remove two E-rings and remove the paper feed roller.
(20) Remove three E-rings and remove the clutch unit.

4.6 Manual paper feed section


4.6.1 List of parts
No.

Part name Ref.

Manual transport roller

Cassette detection switch

PPD1 sensor PWB

Side door detection unit

4.6.2 Disassembly procedure


(1) Remove the screw and remove the single upper cover.

4.5.3 Assembly procedure


For assembly, reverse the disassembly procedure.

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Service Manual

4-13

(2) Remove the screw and remove the side door detection
unit.

(4) Remove the PPD1 sensor PWB.

(3) Remove three screws and remove the single manual


feed upper frame.

(5) Remove the E-ring and remove the manual paper feed
transport roller.

4-14

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Y101700-5

(6) Remove the cassette detection switch.

4.7 Rear frame section


4.7.1 List of parts
No.

Part name Ref.

1
2
3

Mirror motor
Main motor
Exhaust fan motor

4.7.2 Disassembly procedure


(1) Remove three screws and remove the rear cabinet.

(2) Remove two screws, the harness, and the mirror motor.

(7) Remove the multi cover.

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Service Manual

4-15

(3) Remove two screws and one harness, and remove the
main motor.

4.8 Power section


4.8.1 List of parts
No.
1

Part name Ref.


Power PWB

4.8.2 Disassembly procedure


(1) Remove two screws and one connector, and remove the
power PWB.

(4) Remove two screws and one connector, and remove the
exhaust fan motor.

4.8.3 Assembly procedure


For assembly, reverse the disassembly procedure.

4.7.3 Assembly procedure


For assembly, reverse the disassembly procedure.

4-16

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Y101700-5

5.

5.1.1.3 Adjustment procedure


1) Remove the right cabinet (manual paper feed unit), the
document reference plate.
2) Remove the document glass.

ADJUSTMENTS

5.1 Image distortion adjustment


There are following two types of image distortion.
Horizontal image distortion
Vertical image distortion
In this machine, the image distortion is adjusted by
changing the parallelism of mirrors (copy lamp unit,
No. 2/3 mirror unit).

5.1.1 Horizontal image distortion adjustment


Parallelism of mirrors can be made by installing the copy
lamp unit and No. 2/3 mirror unit to the reference position.
However, it must be checked by making a copy, and
must be adjusted if necessary.
5.1.1.1 Cases when the adjustment is required
1) When the copy lamp unit and No.2/3 mirror unit are
disassembled or their part is replaced.
2) When the copy lamp unit and No.2/3 mirror unit drive
section is disassembled or its part is replaced.
3) When the copy image is distorted as shown below:

3) Loosen the fixing screw of the copy lamp unit wire.

5.1.1.2 Necessary tools


Screwdriver (+)
Hex wrench
Scale
Test chart for distortion adjustment (Make a chart
shown below by yourself.)
Draw a rectangle on a paper (B4 or 8 1/2 x 14)
as shown below.
Be sure to make four right angles.

4) Manually turn the copy lamp unit/No.2/3 mirror unit drive


gear to bring No.2/3 mirror unit into contact with No.2/3
mirror unit positioning plate. When No.2/3 mirror unit
makes contact with No.2/3 mirror unit positioning plate in
the Freat and rear frameside simultaneously, the
mechanical parallelism of No.2/3 mirror unit is proper.
If one side of No.2/3 mirror unit makes contact with
No. 2/3 mirror unit positioning plate and the other side
does not, the parallelism is improper.
If the parallelism is improper, perform the procedure of
step 5.

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5-1

7) Manually turn the copy lamp unit/No.2/3 mirror unit drive


gear to bring No.2/3 mirror unit into contact with the
positioning plate, and perform the procedure of step 4.
Repeat procedures of steps 4 to 7 until the parallelism of
No.2/3 mirror unit is properly set.
8) With No.2/3 mirror unit positioning plate in contact with
No.2/3 mirror unit, bring the copy lamp unit into contact
with the right frame and fix the copy lamp unit to the drive
wire. Procedures 1 to 8 are for adjustment of mechanical
horizontal parallelism. The copy lamp unit and No.2/3
mirror are fixed to the specified positions and the
mechanical horizontal parallelism of No.2/3 mirror is
adjusted. Then the optical horizontal parallelism must be
adjusted in the following procedures.

5) Loosen the copy lamp unit/No.2/3 mirror unit drive pulley


setscrew in the side where No.2/3 mirror unit does not
make contact with No.2/3 mirror unit positioning plate.

6) Without moving the copy lamp unit/No.2/3 mirror unit


drive pulley shaft, manually turn the copy lamp unit/
No.2/3 mirror unit drive pulley in the same direction of
the loosened setscrew. When it makes contact with
No.2/3 mirror unit positioning plate, tighten and fix the
setscrew.

5-2

9) Set the image distortion check chart on the document


table, and make a reduction copy (75%) on an A4 or 11
x 8 1/2 paper with the document cover open.

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Y101700-5

10) Check the horizontal image distortion.


If LL = LR, there is no horizontal distortion

5.1.2 Vertical image distortion adjustment


In this adjustment, the left and right balance is adjusted by
changing the left and right balance of the No. 2 scanner unit
frame on the front frame side.
5.1.2.1 Note
Horizontal image distortion adjustment
5.1.2.2 Cases when the adjustment is required
1) When the copy lamp unit/No.2/3 mirror unit drive
section is disassembled or its part is replaced.
2) When the copy image is distorted as follows:

11) If LL is not equal to LR, perform the following procedure.


Loosen the setscrew of the copy lamp unit/No.2/3 mirror
unit drive pulley in the front or the rear frame.

5.1.2.3 Necessary tools


Screwdriver (+)
Screwdriver ()
Scale
Test chart for distortion adjustment (Make
yourself). Draw a rectangle on A4 or 8 1/2 x 11
paper as shown below:
Be sure to make four right angles.

12) Without moving the copy lamp unit/No.2/3 mirror unit


drive pulley shaft, manually turn the copy lamp unit/
No.2/3 mirror unit drive pulley whose setscrew was
loosened, and adjust the parallelism of copy lamp unit/
No.2/3 mirror unit.
5.1.2.4 Adjustment procedure
1) Set the test chart for image distortion adjustment on the
document glass, and make a normal copy on a paper of
A4 or 8 1/2 x 11.
2) Check image distortion in the right and the left sides.If the
both vertical lines are in parallel with each other, the
rightleft distortion balance is proper. (However, there
may be some distortion).
If all the four angles are right angles, there in no distortion
and the following procedures are not required.

13) Tighten the set screw of the copy lamp unit/No.2/3 mirror
unit drive pulley.
14) Check the image distortion in the same manner as step
10. Repeat procedures 11 to 14 until horizontal image
distortion is eliminated.

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Service Manual

5-3

3) If the right-left distortion balance is improper, loosen the


fixing screw of No.2/3 mirror unit rail to change and adjust
the right-left balance of No.2/3 mirror unit rail.

The main scanning (front/rear) direction magnification ratio


adjustment is made automatically or manually.
Automatic adjustment: The width of the reference line marked
on the shading correction plate is scanned to perform the
main scanning (front/rear) direction magnification ratio adjustment automatically.
Manual adjustment: The adjustment is made by manual key
operations. (In either of the automatic and manual adjustments, the zoom data register set value is changed for adjustment). The magnification ratio in the sub scanning direction is
adjusted by changing the mirror base (scanner) scanning
speed.

5.2.1 Main scanning direction magnification


ratio adjustment

Note:
If the distortion in the lead edge side (when viewed in the
paper transport direction) is greater, change the height of
the left rail of No.2/3 mirror unit.
If the distortion in the rear edge side (when viewed in the
paper transport direction) is greater, change the height of
the right rail of No.2/3 mirror unit.

Before performing this adjustment, the following adjustments


must have been completed. If not, this adjustment cannot be
performed properly.
Image distortion adjustment
The lens unit must be installed in the reference position.
5.2.1.1 Cases when the adjustment is required
1) When the lens and the mirror unit are disassembled or the
part is replaced.
2) When the copy lamp unit/No.2/3 mirror unit drive section
is disassembled
or the part is replaced.
3) When the main PWB is replaced.
4) When the EEPROM in the main PWB is replaced.
5) When U2 trouble occurs.
6) When the copy image distortion adjustment is performed.
5.2.1.2 Necessary tools
Screwdriver (+)
Scale
5.2.1.3 Adjustment procedure
1) Set the scale vertically on the document table. (Use a
long scale for precise adjustment.)

4) Make a copy to check the vertical image distortion.


If the four angles are right angles, the adjustment is
completed.

5.2 Copy magnification ratio adjustment


The copy magnification ratio must be adjusted in the main
scanning direction and in the sub scanning direction.
To adjust, use SIM 48-1.

2) Set the copy magnification ratio to 100%.


3) Make a copy on A4 or 81/2 x 11 paper.

5-4

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Y101700-5

4) Measure the length of the copied scale image.

5) Calculate the main scanning direction magnification ratio.


Main scanning direction magnification ratio
=

Copy image dimensions


Original dimension

6) Check that the copy magnification ratio is within the


specified range. If it is not within the specified range,
perform the following procedures.
7) Execute SIM 48-1 to select the main scanning direction
copy magnification ratio adjustment mode. To select the
adjustment mode, use the copy mode select key.
In the case of the automatic adjustment, when the PRINT
switch is pressed, the mirror base unit moves to the white
plate for shading to scan the width of the reference line,
calculating the correction value and displaying and storing
this value.
After execution of the automatic adjustment, go out from
the simulation mode and make a copy to check the
magnification ratio. If the magnification ratio is not in the
specified range (100 1.0%), manually adjust as follows.

Adjustment mode

100 (%)

5.2.2.1 Cases when the adjustment is required


1) When the lens and the mirror unit are disassembled or the
part is replaced.
2) When the scanner unit drive section is disassembled or
the part is replaced.
3) When the main PWB is replaced.
4) When the EEPROM in the main PWB is replaced.
5) When U2 trouble occurs.
6) When the copy image distortion adjustment is performed.
5.2.2.2 Necessary tools
Screwdriver (+)
Scale
5.2.2.3 Adjustment procedure
1) Set the scale on the document table as shown below.
(Use a long scale for precise adjustment.)

Lighting lamp

Main scanning direction auto


copy magnification ratio
adjustment

Auto exposure lamp


ON

Main scanning direction manual


copy magnification ratio

Manual exposure lamp


ON

adjustment
Sub scanning direction copy
magnification ratio adjustment

Photo exposure lamp


ON

8) Set the adjustment mode to Manual with the copy mode


select key.
9) Enter the new set value of main scanning direction copy
magnification ratio with the copy quantity set key, and
press the COPY button.
10) Change the set value and repeat the adjustment until the
ratio is within the speoified range.
When the set value is changed by 1, the magnification
ratio is changed by 0.1%.

5.2.2 Sub scanning direction copy


magnification ratio
Before performing this adjustment, the following
adjustments must have been completed. If not, this
adjustment cannot be performed properly.
Image distortion adjustment
Must be installed to the lens unit reference position.

Y101700-5

2) Set the copy magnification ratio to 100%.


3) Make a copy on A4 or 81/2 x 11 paper.
4) Measure the length of the copied scale image.
5) Calculate the sub scanning direction copy magnification
ratio.
Copy image dimensions

Service Manual

Original dimension

100 (%)

5-5

6) Check that the actual copy magnification ratio is within


the specified range. (100 1.0%).
If it is not within the specified range, perform the following
procedures.

5.2.4 Image position adjustment


There are following five kinds of image position adjustments,
which are made by laser control except for the image scan
start position adjustment. For the adjustments, SIM 50 01
and SIM 50 10 are used.

7) Execute SIM 48-1 to select the sub scanning direction


copy magnification ratio adjustment mode. To select the
adjustment mode, use the copy mode select key.
(Photo exposure lamp ON)

No.

Adjustment item

Print start position

50 01

8) Enter the new set value of sub scanning direction copy


magnification ratio with the copy quantity set key, and
press the COPY button.

Image lead edge void amount

50 01

Image scan start position

50 01

Image rear edge void amount

50 01

Center offset

50 10

Repeat procedures 1-8 until the sub scanning direction


actual copy magnification ratio in 100% copying is within
the specified range.
When the set value is changed by 1, the magnification
ratio is changed by 0.1%.

5.2.3 Lens unit attachment reference


Attach the lens unit so that the lens unit number on the lens
adjustment plate is aligned with the scribe line on the base
plate.

To select the adjustment mode with SIM 50 01, use the copy
density select key.
The relationship between the adjustment modes and the
lighting lamps are as shown in the table below.

Adjustment mode

Lighting lamp

Print start position

Auto (AE) lamp

Image lead edge void amount

Manual (TEXT)
lamp

Image scan start position

Photo lamp

Image rear edge void amount

Auto, Manual,
Photo lamps

Example: Lens unit number 2.8


Attach the lens unit at 2 scales in the paper
exit direction from the reference line.
Note: Never touch the other screws than the unit attachment
screw. The lens unit is supplied only in a whole unit.

5-6

Simulation

To select the adjustment mode with SIM 50 10, use the


copy mode select key.

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Y101700-5

The relationship between the adjustment modes and the


lighting lamps are as shown in the table below
Machine with the multi manual paper feed unit.

Adjustment mode

Lighting lamp

Print center offset (cassette)

Auto, Cassette

Print center offset (manual feed)

Auto, Manual

Document center offset

Auto, Manual
5.2.4.2 Image rear edge void amount adjustment
1) Set a scale to the rear edge section of A4 or
11 x 8 1/2 paper size as shown in the figure below, and
cover it with B4 or 8 1/2 x 14 paper.

Machine with the single manual paper feed unit

Print center offset (cassette)

Auto, Cassette

Print center offset (manual feed)

Auto

Document center offset

Auto, Manual

5.2.4.1 Lead edge adjustment


1) Set a scale to the center of the paper lead edge guide as
shown below, and cover it with B4 or 8 1/2 x 14 paper.

2) Execute SIM 50 01 to select the image rear edge void


amount adjustment mode.
The set adjustment value is displayed on the copy
quantity display.
3) Make a copy and measure the void amount of image rear
edge.

2) Execute SIM 50 01
3) Set the print start position (AE lamp ON) (A), the lead
edge void amount (TEXT lamp ON) (B), and the scan
start position (PHOTO lamp ON) (C) to 0, and make a
copy of a scale at 100%.
4) Measure the image loss amount (R mm) of the scale
image. Set C = 10 x R (mm). (Example: Set the value of
C to 30.) When the value of C is increased by 10, the
image loss is decreased by 1mm. (Default: 50)
5) Measure the distance (H mm) between the paper lead
edge and the image print start position. Set A = 10 x H
(mm). (Example: Set the value of A to 50.)
When the value of A is increased by 10, the image lead
edge is shifted to the paper lead edge by 1mm.
(Default: 50)
6) Set the lead edge void amount to B = 50 (2.5mm).
When the value of B is increased by 10, the void amount
is increased by about 1mm. For 25 or less, however, the
void amount becomes zero. (Default: 50)

Y101700-5

4) If the measurement value is out of the specified range,


change the set value and repeat the adjustment procedure.
The default value is 50.
Note:
The rear edge void cannot be checked with
the first sheet after entering the simulation
mode, the first sheet after turning off/on the
power, or the first sheet after inserting the
cassette. Use the second or later sheet to
check the rear edge void.
5.2.4.3 Center offset adjustment
1) Set the self-made test chart for the center position
adjustment so that its center line is aligned with the center
mark of the document guide.
Test chart for the center position adjustment
Draw a line at the center of A4 or 8 1/2 x 11 paper
in the paper transport direction.

Service Manual

5-7

5.3.2 Note for copy density adjustment


5.3.2.1 Arrangement before execution of the copy
density adjustment
Clean the optical section.
Clean or replace the charger wire.
Check that the voltage at the high voltage section and
the developing bias voltage are in the specified range.

5.3.3 Necessary tool for copy density


adjustment
2) Execute SIM 50 10 to select the print center offset
(cassette paper feed) adjustment mode. The set
adjustment value is displayed on the copy quantity display.
3) Make a copy and check that the copied center line is
properly positioned.
The standard value is 0 2mm from the paper center.

One of the following test charts:


UKOG-0162FCZZ, UKOG-0089CSZZ, KODAK GRAY
SCALE
B4 (14 x 8 1/2) white paper
The user program AE setting should be 3.

Test chart comparison table

4) If the measured value is out of the specified range,


change the set value and repeat the adjustment procedure.
When the set value is increased by 1, the copy image is
shifted by 0.1mm toward the rear frame.
For the manual paper feed, change the manual
paper feed adjustment mode and perform the
similar procedures.
Since the document center offset is automatically
adjusted by the CCD which scan the reference
lines (F/R) on the back of document guide, there is
no need to adjust manually.

5.3.4 Features of copy density adjustment


For the copy density adjustment, the image data shift function
provided in the image process LSI is used.
List of the adjustment modes.
Auto Mode
Manual Mode

Brightness 1 step only


Brightness 5 steps. Adjustment of
only the center brightness is made.

5.3 Copy density adjustment


Photo Mode

only the center brightness is made.

5.3.1 Copy density adjustment timing


The copy density adjustment must be performed in the
following cases:
When maintenance is performed.
When the developing bias/grid bias voltage is adjusted.
When the optical section is cleaned.
When a part in the optical section is replaced.
When the optical section is disassembled.
When the OPC drum is replaced.
When the main control PWB is replaced.
When the EEPROM on the main control PWB is
replaced.
When the memory trouble (U2) occurs.

5-8

Brightness 5 steps. Adjustment of

Manual T/S

Brightness 5 steps. Adjustment


of only the mode
center brightness is made.

T/S Auto mode

Service Manual

Brightness 1 step only

Y101700-5

5.3.5 Copy density adjustment procedure


Use SIM 46-01 to set the copy density for each copy mode.
For selection of modes, use the copy mode select key.
5.3.5.1 Test chart (UKOG-0162FCZZ) setting
1) Place the test chart so that its edge is aligned with the
A4 (Letter) reference line on the document table. Then
place a B4 (14 x 8 1/2) white paper on the test chart
and close the document cover.

3) Make a copy.
Check the adjustment level (shown in the above table) of
the exposure test chart (Gray Scale).

5.3.5.2 Perform the adjustment in each mode.


1) Execute SIM 46-1.
2) Select the mode to be adjusted with the exposure mode
select key. Set the exposure level to 3 for all adjustment.
(Except for the auto mode.)

(When too bright): Decrease the value displayed on the


copy quantity display.
(When too dark): Increase the value displayed on the
copy quantity display.
* The value can be set in the range of 1 - 99.

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Service Manual

5-9

5.4 High voltage adjustment

5.4.2 DV bias adjustment

5.4.1 Main charger (Grid bias)

A digital multi meter with internal resistance of 1GW


must be used for correct adjustment.

Use a digital multi meter with internal resistance of


10MW or more measurement.
After adjusting the grid LOW output, adjust the HIGH
output.
Do not reverse the sequence.

5.4.2.1 Procedures

5.4.1.1 Procedures
1. Set the digital multi meter range to DC700V.
2. Set the positive side of the test rod to the connector
CN11-3 (GRID) of high voltage section of the power PWB
and set the negative side to the frame ground (radiating
plate).
3. Execute SIM 8-3. (The main charger output is supplied for
30 sec in the grid voltage LOW output mode.)
4. Adjust the control volume (VR-141) so that the output
voltage is 400 20V.
5. Execute SIM 8-2. (The main charger output is supplied for
30 sec in the grid voltage HIGH output mode.)
6. Adjust the control volume (VR-142) so that the output
voltage is 580 10V.

5-10

1. Set the digital multi meter range to DC500V.


2. Set the positive side of the test rod to the connector
CN-10-1 (DV BIAS) and set the negative side to the
connector CN10-2 (FG).
3. Execute SIM 8-1. (The developing bias is outputted for
30 sec.)
4. Adjust the control volume (VR-121) so that the output
voltage is 400 5V.

Service Manual

Y101700-5

6. SIMULATIONS AND TROUBLE CODES


6.1 Simulations
6.1.1 List of simulations
Sim No.

Kind of main code Sub code

Operation

01

Optical system

01

Mirror scan operation

05

Lamp ON
check

01
02
03

Operation panel display check


Fusing lamp ON + Cooling fan HIGH/LOW speed
Copy lamp ON

06

Machine
individual
load
operation

01
02

Paper feed solenoid ON


Resist solenoid ON

07

Aging

01
06

Warm up display and aging with jam


Intermittent aging

08

High
voltage
output check

01
02
03
06

Developing bias
Main charger (Grid high)
Grid Voltage (Low)
Transfer charger.

10

Other

None

Toner motor aging

14

Trouble
reset

None

Cancel troubles other than U2

16

U2 Trouble
reset

None

Cancel of U2 trouble

20

Manteinance
counter clear

01

Manteinance/mini-manteinance
counter clear

21

Counter setup
(When
manteinance)

01
02

Manteinance cycle setup


Mini-manteinance cycle setup

22

Counter
display

01
02
05
06
12
14

Maintenance/mini-maintenance counter display


Maintenance/mini-maintenance preset display
Total counter display
Developer counter display
Drum counter display
P-ROM version display

24

Special counter
clear

06
07

Developer counter clear


Drum counter clear

25

Main motor ON

01
10

Main motor system ON + Cooling fan low speed


Poligon motor ON

Y101700-5

Service Manual

6-1

Sim No.

Kind of main code Sub code

Operation

26

Various setup

01
02
03
04
06
07
20
30
37
39
40
42
43

Manual feed setup


SPF setup
Second cassette setup
Machine duplex setup
Destination setup
Machine conditions check
Rear edge void setup
CE mark conformity control ON/OFF setup
Cancel of stop at developer over
Memory capacity setup
Polygon motor OFF time setup
Transfer ON timing control setup
Side void setup

30

Sensor operation
check (standard
provision)

01

Paper sensor display status

43

Fusing temp.
setup

01
04

Normal copy
Fusing temperature setup 2

46

Exposure
adjustment

01
19

Copy density adjustment


Gamma table adjustment (Copy mode)

48

Magnification
ratio correction

01

Front/rear scan ditrection

50

Lead edge
adjustment

01
10

Lead edge image position adjustment


Paper lead edge/rear edge void adjustment
Paper center offset + OC/Document center offset

51

Timing
adjustment

02

Resist quantity adjustment

61

Laser system
operation

03

Pligon motor check (HSYNC output check)

63

Shading

01

Shading check

64

Self print

01

Self print only with the engine (1 by 2 mode)

6-2

Service Manual

Y101700-5

Main code
01

Content

Sub code
01

Mirror scan operation


(Operation/Procedure)
1. When this simulation is executed, the mirror home position is detected.
Sensor name
Mirror home position sensor

Display lamp
OPC drum cartridge replacement lamp

2. When the _START key is pressed, scanning is executed at the speed corresponding
to the currently set copy magnification ratio.
The copy magnification ratio can be arbitrarily set with the magnification ratio select
key/zoom key.
05

06

07

Y101700-5

01

Operation panel display check


When the PRINT switch is pressed, the LED on the operation panel is lighted for 5 sec.

02

Fusing lamp ON + cooling fan HIGH/LOW speed


(Operation/Procedure)
When the START key is pressed, the fusing lamp repeats ON (500ms) and OFF
(500msec) 5 times.
During this period, the cooling fan rotates in the high speed mode. After completion of
the operation, the cooling fan rotates in the low speed mode.

03

Copy lamp ON
(Operation/Procedure)
When the START key is pressed, the copy lamp is lighted for 5 sec.

01

Paper feed solenoid ON


(Operation/Procedure)
When the START key is pressed, the paper feed solenoid selected by the tray select key
repeats ON (500ms) and OFF (500ms) 20 times.

02

Resist solenoid ON
(Operation/Procedure)
When the START key is pressed, the resist solenoid (RRS) repeats ON (500ms) and
OFF (500ms) 20 times.

01

Warm-up display and aging with jam


(Operation/Procedure)
1. When the simulation is executed, warming up is started.
2. Warm-up time is counted and displayed every second on the copy quantity display.
3. After completion of warm-up, the time count is stopped and the ready lamp is lighted.
4. Press the clear key to clear the warm-up time display, set the copy quantity, and
press the START key, and the machine will copy the set quantity repeatedly.

02

Intermittent aging
(Operation/Procedure)
1. When the simulation is executed, warming up is started.
2. After completion of warm-up, the ready lamp is lighted.
3. Set the copy quantity and press the START key, and the machine will copy the set
quantity repeatedly.
4. After 3 sec of the interval time from completion of copying the set quantity, the
machine will resume copying.
5. The above operation 4 is repeated.

Service Manual

6-3

Main code
08

01

Developing bias
(Operation/Procedure)
When the START key is pressed, the developing bias is outputted for 30 sec.

02

Main charger (Grid high)


(Operation/Procedure)
When the START key is pressed, the main charger output is supplied for 30 sec in the
grid

03

Grid voltage (Low)


(Operation/Procedure)
When the START key is pressed, the main charger output is supplied for 30 sec in the
grid

06

Transfer charger
(Operation/Procedure)
When the START key is pressed, the transfer charger output is supplied for 30 sec.

10

None

Toner motor aging


(Operation/Procedure)
When the START key is pressed, the toner motor output is supplied for 30 sec.

14

None

Cancel of troubles other than U2


(Operation/Procedure)
After canceling the trouble, the simulation is also automatically canceled.

16

None

Cancel of U2 trouble
(Operation/Procedure)
1. When the START key is pressed, the EEPROM total counter check sum is rewritten
and the trouble is canceled.
2. After canceling the trouble, the simulation is also automatically canceled.

20

01

Maintenance/mini-maintenance counter clear


When the Print switch is pressed, the maintenance counter is cleared, and 000000 is
displayed. When the destination has been set to Japan AB series, the mini-maintenance
counter is cleared.

21

01

Maintenance cycle setup


The currently set maintenance cycle code is displayed (initial display), and the set data
is stored.

02

6-4

Content

Sub code

Code

Setup

0
1
2
3
4
5

3,000 sheets
6,000 sheets
9,000 sheets
13,000 sheets
25,000 sheets
Free (999,999 sheets) * Default

Mini-maintenance cycle setup (Valid only when the destination is set to Japan AB
series.)
The current set code of maintenance cycle is displayed (Initial display), and the set data
is stored.
Code

Setup

0
1
2

5,000 sheets * Default


10,000 sheets
Free (999,999 sheets)

Service Manual

Y101700-5

Main code
22

24

Y101700-5

Sub code

Content

01

Maintenance/mini-maintenance counter display


The display is the same as the total counter value display.
When the destination is set to other than Japan AB series, the maintenance counter is
displayed.
When the destination is set to Japan AB series, the mini-maintenance counter is
displayed. The display is the same as the total counter value display.

02

Maintenance/mini-maintenance preset display


The preset value corresponding to the code set in 21-01 and 21-02.
The display is the same as the total counter value display.
When the destination is set to other than Japan AB series, the maintenance preset value
is displayed.
When the destination is set to Japan AB series, the mini-maintenance preset value is
displayed.

05

Total counter display


The total count value is displayed in 3 digits 2 times repeatedly.
<Display example: 12345>
012 Blank 345 Blank 012
0.7s
0.3s
0.7s
1.0s
0.7s

06

Developer counter display


The display method is the same as the total count value display.

12

Drum counter display


The display method is the same as the total count value display.

14

P-ROM version display


The P-ROM version is displayed in 3 digits on the value display section.
(100% Zoom lamp display)

06

Developer counter clear


When the PRINT switch is pressed, the drum count value is reset to 0.

07

Drum counter clear


When the PRINT switch is pressed, the drum count value is reset to 0.

Service Manual

6-5

Main code
25

26

Content

Sub code
01

Main motor system ON + Cooling fan low speed


(Operation/Procedure)
When the START key is pressed, the main motor is rotated for 30 sec.
To save toner consumption, the different operations are executed depending on
installation of the developing unit.
When the developing unit is installed, the developing bias, the main charger, and the
grid are also outputted.
When the developing unit is not installed, only the motor is rotated.
* Do not turn on the door open/close switch forcibly to execute this simulation.

10

Polygon motor ON
(Operation/Procedure)
When the START key is pressed, the polygon motor is operated for 30sec.

01

Manual feed setup


(Operation/Procedure)
1. When this simulation is executed, the currently set bypass code number is displayed.
2. Enter the code number corresponding to the bypass and press the START key, and
the setting will bechanged.

02

Code number

Bypass

0
1

Single bypass
Multi bypass

SPF setup
When this simulation is executed, the currently set SPF code number is
displayed. Enter the code number of the SPF to be set and press the PRINT switch. The
setup is changed.
Code number

SPF

0
1

Without SPF
With SPF (Setup required
when installing FAX)
With RSPF

03

6-6

Second cassette setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number of the second
cassette is displayed.
2. Enter the code number and press the Start key. The setting is changed.

Code number

Second cassette

0
1

Without second cassette


With second cassette

Service Manual

Y101700-5

Main code
26

Sub code
04

06

07

Content
Machine duplex setup
(Operation/Procedure)
1. When this simulation is executed, the currently set duplex code number is displayed.
2. Enter the code number corresponding to the duplex and press the ENTER key and the
setup will be changed.
Code number

Duplex

0
1

Without duplex
With duplex

Destination setup
(Operation/Procedure)
1. When this emulation is executed, the currently set destination code number is
displayed.
2. Enter the code number corresponding to the destination and press the START key,
and the setting will be changed.
Code number

Destination

0
1
2

Inch series
EX AB series
Japan AB series

Machine conditions check


(Operation/Procedure)
When this simulation is executed, the current machine setting is displayed.

CPM

Copy quantity display

10 cpm
12 cpm
15 cpm

10
12
15

The machine type is shown with the lamp display.


No setup: None
BTA-A: AE mode lamp ON
BTA-B: TEXT mode lamp ON
BTA-C: Photo mode lamp ON

Y101700-5

Service Manual

6-7

Main code
26

20

30

37

39

6-8

Content

Sub code

Rear edge void setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number of rear edge void
setting is displayed.
2. Enter the code number of rear edge void setting and press the START key, and the
setting will be changed.

Code number

Rear edge void setting

0
1

Rear edge void allowed


Rear edge void not allowed

CE mark conformity control ON/OFF setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number of CE mark
application is displayed.
2. Enter the code number of CE mark application and press the START key, and the
setting will be changed.

Code number

CE mark application setting

0
1

CE mark application control OFF


CE mark application control ON

Cancel of stop at developer life over


When this simulation is executed, the current set code is displayed. Enter a new code
and press the PRINT switch, and the entered code is registered.

Code number

Setting

0
1

Stop at developer life over


Stop cancel at developer life over

Memory capacity setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number is displayed.
2. Enter the code number and press the START key, and the setting will be changed.

Code number

Setting

0
1
2

No memory
4 Mbyte
6 Mbyte

Service Manual

Y101700-5

Main code
26

40

42

43

Y101700-5

Content

Sub code

Polygon motor OFF time setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number is displayed.
2. Enter the code number and press the START key, and the setting will be changed.

Code number

Setting

0
1
2
3

0 sec
30 sec
60 sec
90 sec

Transfer ON timing control setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number is displayed.
2. Enter the code number and press the START key, and the setting will be changed.
(For any number different from the following ones, the default time is automatically
set.)

Code number

Setting

0
1
2
3
4
5
6
7
8
9

Default (330 msec)


40 msec
30 msec
20 msec
10 msec
Default (330 msec)
+10 msec
+20 msec
+30 msec
+40 msec

Side void setup


(Operation/Procedure)
1. When this simulation is executed, the currently set code number of the side void
amount is displayed.
2. Enter the code number and press the start key. The setting is changed.

Code number

Setting

0
1
2
3
4
5
6
7
8
9
10

0 mm
0.5 mm
1.0 mm
1.5 mm
2.0 mm *Default
2.5 mm
3.0 mm
3.5 mm
4.0 mm
4.5 mm
5.0 mm

Service Manual

6-9

Main code
30

Sub code
01

Content
Paper sensor status display
The paper sensor status is displayed with the lamps on the operation panel.

Display

Sensor

Toner cartridge replacement lamp


JAM lamp
Developer cartridge replacement lamp
AE lamp

Paper detection before resist (PPD1)


Fusing section paper detection (PPD2)
Paper exit paper detection (POD)
Single manual feed paper
detection (MFD)
Cassette A4 width detection (PSW1)

Exposure level 1 (Light) lamp

43

6-10

01

Fusing temperature setup (Normal copy)


(Operation/Procedure)
1. When this simulation is executed, the currently set code number is displayed.
2. Enter the code number and press the START key, and the setting will be changed.

Code number

Set temperature (C)

0
1
2
3
4
5

175
180
185
190
195 (* Default)
200

Service Manual

Y101700-5

Main code
46

Content

Sub code
01

Copy density adjustment


(Outline)
Used to adjust the copy density in each copy mode. (The copy density can be set by
changing the set value of ASIC GAMMA ADJUST register.)
Setting in each copy mode is performed at exposure level 3. When the copy density
(exposure) is adjusted arbitrarily, the max, and min. exposure levels are automatically
calculated and set. (The change amounts (gradient, change amount) at level 1 5 are
predetermined.)
(Operation/Procedure)
1. When this simulation is executed, warming up and shading are performed and the
current set value is displayed in two digits.
2. Press the copy mode select key to select each setting mode and setting display.
* The copy mode setting is indicated with the following lamps as shown below.
3. Change the setting with the value up-down key and press the START key, and a
copy will be made with the entered set value.
4. Press the clear key to store the set value and exit the simulation.

Copy mode

Display lamp

AE mode
TEXT mode
PHOTO mode
TS mode (TEXT)
TS mode (AE)

AE mode lamp
TEXT mode lamp
PHOTO mode lamp
TEXT mode lamp & PHOTO mode lamp
AE mode lamp & PHOTO mode lamp

Relationship between the displayed values and the GAMMA ADJUST register

AE
TEXT
PHOTO
T/S

Exp1

Exp2

Exp3

Exp4

24
24
24
24

12
12
12
12

0
0
0
0

+12
+12
+12
+12

Exp5
+24
+24
+24
+24

The value displayed after execution of this simulation can be set in the range of 0 99
with 50 as the center value.
When the text mode set value is Gat3, for example, the GAMMA ADJUST register value
set at Exp1 is:
Text Exp1 = Gat3 50 24
When 40 is set to Gat3, Text Exp1 = 40 50 24 = 34
Then set the GAMMA ADJUST register set value to 34.
Perform the same procedure for each mode and each Exp.
* The above table may subject to change.
* For the gradient, there is a similar table, though not specified here. The value set with
SIM 46, however, is not reflected.
* The AE mode Exp selection is not specified, but corresponds to the grades for AE
exposure selection in the former models.

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Service Manual

6-11

Main code
46

48

Content

Sub code
19

01

Gamma table setup


When this simulation is executed, the currently set gamma table code number is
displayed. Enter the code number corresponding to your desired gamma table and
press the PRINT switch, and the setup will be changed.

Code number

Gamma table

1
2

Japan
EX Japan

Front/rear scan direction


(Outline)
(1) Front/rear scanning direction magnification ratio auto correction: (Performed by
changing the set value of ZOOM DATA register for asic.) The width of the reference
line marked on the shading correction plate is scanned to perform the front/rear
direction magnification ratio adjustment automatically. (Performed by changing the
set value of ZOOM DATA register for ASIC.)
(2) Front/rear scanning direction magnification ratio manual correction: Used to set the
front/rear (main scanning) direction magnification ratio by key operations. (Performed
by changing the set value of ZOOM DATA register for ASIC.)
(3) Scanning direction magnification ratio correction: The scanning direction
magnification ratio in the OC mode is set by key operations. (Performed by changing
the scanning speed.)
(Operation/Procedure)
1. When this simulation is executed, the current set value is displayed in two digits.
(Center value: 50)
2. When the copy mode select key is pressed, the setting mode and the setting display
are changed sequentially.
* The selected adjustment mode is indicated by the lamps as follows:
3. In the front/rear scanning direction adjustment, when the START key is pressed, the
mirror base unit moves to the white plate for shading and the width of the reference
line is read and the correction value is calculated and displayed and the value is
stored. In the case of the manual adjustment, enter the adjustment value with the 10key and press the START key. Then the entered value is stored and a copy is made.
(An increase of 1 in the set value corresponds to an increase of 0.1mm.)
4. Press the clear key to store the set value and exit the simulation.

Adjustment mode

Lamps ON

Front/rear direction magnification ratio auto correction


Front/rear direction magnification ratio manual correction
Scanning direction magnification ratio correction

AE lamp
TEXT lamp
PHOTO lamp

In the front-rear direction magnification ratio correction:


(1) The result of calculation of the scan correction value is 5% or less, - - is displayed.
(Cause) The white plate reference position error or the lens unit installing error
(2) In case of a scanning error of the reference line, the JAM lamp is turned on.
(Cause) CCD error or no white plate
) If the automatic correction of magnification ratio does not work properly, adjust and
correct manually.

6-12

Service Manual

Y101700-5

Main code
50

Content

Sub code
01

Lead edge image position adjustment + Paper lead edge/rear edge void adjustment
(Outline)
This adjustment is used to adjust the copy image position and lead edge/rear edge void
amount on the copy paper by adjusting the image scan start position and the print start
position (resist roller ON timing) at 100%.
(Operation/Procedure)
1. When this simulation is executed, the currently set value is displayed in two digits.
(Center value: 50)
2. When the copy mode select key is pressed, each setting mode and the display are
changed.
* The selected adjustment mode is indicated by the lamps as shown in the table
below.
3. Enter the adjustment value with the 10-key and press the start key. The set value is
stored and a copy is made. (When the set value is increased by 1, the void amount is
shifted by 0.1 mm.)
4. When the clear key is pressed, the set value is stored and the simulation mode is
terminated.

Adjustment mode
Print start position (Cassette)
Print start position (Manual paper feed)
Image lead edge void quantity
Image scan start position
Image rear edge void quantity

Lighting lamps
AE, Cassette lamps
AE, Manual feed lamps
TEXT lamp
PHOTO lamp
AE, TEXT, PHOTO lamps

(Adjustment method)
1. Set the print start position (A: AE ON), the lead edge void amount (B: TEXT ON), the
scanning start position (C: PHOTO ON) to zero and make a copy of a scale at 100%.
2. Measure the image loss R (mm) of the scale.
Set as C = 10 R (mm).
(Example: Set to 30.)
* When C is increased by 10, the image loss
is decreased by 1 mm. (Default: 5)
3. Measure the distance H (mm) from the paper
lead edge to the image print start position.
Set as A = 10 R (mm). (Example: Set to 50.)
* When the value of A is increased by 10, the
image lead edge is shifted toward the paper
lead edge by 1 mm. (Default: 50)
4. Set the lead edge void amount as
B = 50 (2.5 mm). (Default: 50)
* When the value of B is increased by 10,
the void is increased by about 1 mm.
(For 25 or less, however, the void amount becomes zero.)

Y101700-5

Service Manual

6-13

Main code
50

Content

Sub code
10

Paper center offset + OC/Document center offset


(Outline)
The center offset position of copy image on the copy paper and that of document scan are
adjusted by adjusting the scan left margin of ASIC and the print left margin register set value.
(Operation/Procedure)
1. When this simulation is executed, the currently set value is displayed.
2. When the copy mode select key is pressed, each set mode and display are changed.
Machine with single manual paper feed

51

02

Adjustment mode

Display lamp

Print center offset (Cassette paper feed)


Print center offset (Manual paper feed)
OC/Document center offset

AE,Cassette lamp
AE lamp (Blinking)
AE, TEXT lamp

Resist quantity adjustment


Used to adjust the contact pressure of paper onto the copier resist roller and the RSPF
resist roller.
(Operation/Procedure)
1. When this simulation is executed, the currently set value is displayed.
2. Press the copy mode select key, and each setting mode and display are changed
sequentially.
* The selected adjustment mode is indicated by the lamps as follows:
3. Enter the adjustment value with the 10-key and press the SORT key. Then the set
value is stored and a copy is made.
4. Press the clear key to store the set value and exit the simulation.
Single manual paper feed

6-14

Adjustment mode

Display lamp

Cassette paper feed


Manual paper feed

AE, Cassette lamp


AE blinking (Cassette lamp ON)

61

03

Polygon motor check (HSYNC output check)


(Operation/Procedure)
When the START key is pressed, HSYNC is performed and the polygon motor is rotated
for 30 sec. At that time, the Zoom lamp is lighted for 100msec every time when HSYNC is
detected.

63

01

Shading check
(Outline)
Used to display the detection level of the white plate for shading. (Vref of AD conversion
IC is fixed.)
(Operation/Procedure)
When the START key is pressed, the mirror base unit moves to the white plate for
shading and Vref+ voltage of AD conversion IC is set to 4.5V and Vref- voltage to 0.5V,
and the copy lamp is lighted.
This state is kept for 10 sec, and the level of one pixel at the center is detected every
second to display on the value display section.

Service Manual

Y101700-5

Main code
64

Y101700-5

Sub code
1

Content
Self print only with the engine (1 by 2 mode)
(Outline)
Used to print in the 1 by 2 mode by ignoring the state of the optical system.
(Operation/Procedure)
1. When this simulation is executed, warming up is made and the ready lamp is lighted.
2. Select with the cassette select key and press the start key. Paper is fed from the
cassette and printing is performed.
In the 1 by 2 mode, one line is printed and two lines are not printed.

Service Manual

6-15

6.2 Trouble codes


6.2.1 List of Trouble Codes
Main code Sub code

Trouble content

Detail of trouble

E7

03

HSYNC not detected.

LSU (laser diode, reception element, APC circuit) trouble


LSU drive circuit (ASIC) trouble

E7

04

CCD white level trouble

CCD drive circuit (CCD PWB, ASIC harness) trouble


Copy lamp lighting trouble (Copy lamp, invertor PWB)

E7

05

CCD black level trouble

CCD drive circuit (CCD PWB, ASIC, harness) trouble

E7

12

Shading trouble (White


correction

Dirt on white plate for scanning white level

E7

14

ASIC connection trouble

Improper connection between CPU and ASIC (pattern cut,


improper connection of lead pin)

E7

15

Copy lamp disconnection


trouble

Copy lamp or copy lamp drive circuit (invertor PWB) trouble


Copy lamp disconnection

E7

16

Abnormal output of laser

LSU (laser diode, reception element, APC circuit) trouble


LSU drive circuit (ASIC) trouble

L1

00

Feeding is not completed


within the specified
time after starting feeding

When the mirror base is returned for the specified time


(6 sec.) in mirror initializing after turning on the power, the
mirror home position sensor (MHPS) does not turn OFF.
Or when the mirror base is fed for the specified time (about
6 sec) after start of copy return, the mirror home position
sensor (MHPS) does not turn OFF.

L3

00

Return is not completed


within the specified time

When the mirror base is returned for the specified time


(6 sec.) in mirror initializing after turning on the power, the
mirror home position sensor (MHPS) does not turn ON
Or when the mirror base is returned for the specified time
(about 6 sec) after start of copy return, the mirror home
position sensor (MHPS) does not turn ON.

L4

01

Main motor lock

When the main motor encoder pulse is not detected for


100 msec.

L6

10

Polygon motor lock

The lock signal (specified rpm signal) does not return within
a certain time (about 20 sec) from starting the polygon motor
rotation.

H2

00

Thermistor open
detection

The fusing thermistor is open.

H3

00

Heat roller abnormally


high temperature

The fusing temperature rises above 240 C.

H4

00

Heat roller abnormally


low temperature

The fusing temperature does not reach 185 C within 27 sec


of turning on the power, or the fusing temperature keeps
at 140 C.

6-16

Service Manual

Y101700-5

Main code Sub code

Trouble content

Detail of trouble

U2

01

Counter sum check error.

When the counter check sum value stored in the EEPROM


is abnormal.

U2

04

EEPROM serial
communication error

When a communication trouble occurs with the EEPROM.

Y101700-5

Service Manual

6-17

7.

MAINTENANCE

7.1 Maintenance table

7.2 Maintenance display system

Y101700-5

Service Manual

7-1

1-14

Service Manual

Y101700-5

8. ELECTRICAL SECTION
8.1 Block diagram
8.1.1 Overall block diagram

Y101700-5

Service Manual

8-1

8.2 MCU PWB unit

8-2

Service Manual

Y101700-5

9. USER PROGRAM
The conditions of factory settings can be changed according to the use conditions.

9.1 Functions that can be set with the user program

Function

Contents

Factory Setting

Auto clear time

When a certain time is passed after the completion of copying, this


function returns to the initial state automatically. The time to reach
the initial state can be set in the range of 30 sec to 120 sec by the
unit of 30 sec. This function can be disabled.

60 sec

Preheat

When the copier is left unused with the power ON, the power
consumption is automatically reduced to about 40Wh/H (* Note).
The time to start this function can be set in the range of 30 sec to
90 sec by the unit of 30 sec. This function cannot be disabled.

30 sec

When this function is operated, the pre-heat lamp on the operation panel
lights up. To return to the initial state, press any key on the operation panel.
(When the COPY button is pressed, a copy is made after returning to the
initial state.)
Auto shut off
timer

When the copier is left unused with the power ON, the power consumption
is automatically reduced to about 18Wh/H (* Note). The time to start this
function can be set in the range of 2 min to 120 min.

5 min

When this function is operated, all the lamps except for the pre-heat lamp
on the operation panel turn off. To return to the initial state, press the
COPY button.
Auto shut off

Used to set or cancel this function

Set

* Note: The power consumption values in preheat and auto shut off may be varied depending on the use conditions.

9.2 Setting the Power Save Modes and Auto Clear Time
1) Press and hold down the light ({) and dark ( ) keys simultaneously for more than 5 seconds until all the
alarm indicators (q , t, s and p ) blink and - - appears in the display.
2) Use the left copy quantity ( ) key to select a user program number (1: auto clear time, 2: preheat mode, 3: auto
power shut-off timer, 5: auto power shut-off mode). The selected number will blink in the left side
of the display.

Function name
Auto clear time
Preheat
Auto shut off timer
Auto shut off

Note:

Y101700-5

Function code
1
2
3
5

If a wrong code is entered press the clear key and enter the correct function code.

Service Manual

9-1

3) Press the Print ( ) key. The entered program number will be steadily lit and the currently selected parameter
number for the program will blink on the right side of the display.
4) Select the desired parameter using the right copy quantity (
right of the display.

Function
Name

Auto clear
time

Set code

0 (Cancel)
1 (30 sec)
*2 (60 sec)
3 (90 sec)
4 (120 sec)
5 (10 sec)

Function
Name

Preheat

Set code

*0 (30 sec)
1 (60 sec)
2 (90 sec)

) key. The entered parameter will blink on the

Function
Name

Auto shut
off timer

Set code

Funtion
Name

0 (2 min)
*1 (5 min)
2 (15 min)
Auto shut
3 (30 min)
off
4 (60 min)
5 (120 min)

Set code

0 (Cancel)
*1 (Setting)

*: Factory setting

5)

Press the print ( ) key. The right-hand number in the display will be steadily lit and the entered value will be
stored.
Note: To change the setting or to set another mode, press the Clear (>) key. The copier will return to step 2).

6)

Press the light ({) or dark (

9-2

) key to return to the normal copy mode.

Service Manual

Y101700-5

UPD
ATING ST
ATUS
UPDA
STA

DATE

02/2002

PAGES UPDATED

1ST EDITION

PAGES

78

CODE

Y101700-5